Molded cross vehicle beam

ABSTRACT

A molded cross vehicle beam which includes a hollow blow molded thermoplastic rigid member that is integrally attached to a rigid support, e.g., a U-shaped metal plate, and at least one attachment element, is described. The rigid support ( 12 ) has a first surface, a second surface and a plurality of perforations having edges. The attachment element(s) ( 81, 84 ) have a first surface, a second surface and a plurality of perforations having edges. The attachment element provides a manner of attaching the molded cross vehicle beam to a separate structure (e.g., the A-pillars of an automobile). A thermoplastic parison precursor of the hollow rigid thermoplastic member ( 15 ) is blow molded against the first surfaces of the rigid support ( 12 ) and the attachment element ( 81, 84 ). Portions of the thermoplastic parison extend through perforations in each of the rigid support ( 12 ) and the attachment element ( 81, 84 ), thereby attaching the hollow thermoplastic rigid member ( 15 ) to the rigid support ( 12 ) and the attachment element ( 81, 84 ). The present invention also relates to a process by which the molded cross vehicle beam is prepared.

DESCRIPTION OF THE INVENTION

The present invention relates to a molded cross vehicle beam, whichincludes a hollow blow molded thermoplastic rigid member that isintegrally attached to a rigid support, e.g., a U-shaped metal plate,and at least one attachment element. The attachment element serves as ameans of attaching the molded cross vehicle beam to a separatestructure, such as the door-pillars of an automobile. A thermoplasticparison precursor of the hollow rigid thermoplastic member is blowmolded against the rigid support and the attachment element. Portions ofthe thermoplastic parison extend through perforations in each of therigid support and the attachment element, thereby attaching the hollowthermoplastic rigid member to the rigid support and the attachmentelement. The present invention also relates to a process by which themolded cross vehicle beam is prepared.

The majority of transportation vehicles, such as automobiles, trucks andbuses, include a cross vehicle beam, which typically spans laterallyacross the forward portion of the passenger or operator compartment. Inthe case of an automobile, the cross vehicle beam (commonly referred toas a cross car beam) is typically located behind the dashboard, and isattached to the door-pillars (A-pillars) of the automobile. The crossvehicle beam, which is typically fabricated from metal, providesrigidity and structural support to the vehicle, e.g., relative to alateral impact upon the vehicle.

The heating, ventilating and air conditioning (HVAC) system of avehicle, such as an automobile, is typically located behind thedashboard. Air is transported through the HVAC system generally by meansof a plastic conduit. Often, the plastic conduit of the HVAC system isattached to and supported by the cross vehicle beam.

Typically the plastic conduit and the cross vehicle beam are separatelyfabricated, and then attached together in a separate step. The plasticconduit and cross vehicle beam e.g., in the form of a metal beam ortube, are typically attached together by means of, for example,fasteners, adhesives, straps and/or brackets. Such attachment methodstypically involve a series of manufacturing steps, and the use ofadditional materials, e.g., rivets, bolts and adhesives. In the case ofan automotive application, for example, the separately fabricated crosscar beam and plastic conduit, when assembled together, can take up anundesirably large amount of space within the passenger compartment.

In the transportation industries, e.g., the automotive and aircraftindustries, it is desirable to minimize the weight of the vehicle oraircraft in an effort towards maximizing fuel efficiency. The totalweight of a vehicle or aircraft can be reduced by reducing the weight ofits components. However, it is generally required that the strength andrigidity of a component not be compromised as the weight of thecomponent is reduced. It is also desirable in the transportationindustries to minimize the space occupied by various components that areincorporated into the vehicle or aircraft.

A need thus exists for the development of cross vehicle beams thatinclude a rigid support and a rigid thermoplastic hollow member attachedthereto, that provide a combination of structural stability, reducedweight and compact (or space saving) design. In addition it is desirablethat such newly developed cross vehicle beams also include a means forattaching the beam to a separate structure, such as the door-pillars ofan automobile. A need also exists with regard to the development of newmethods of preparing such molded articles in which the rigidthermoplastic hollow member is concurrently molded and fixedly attachedto a rigid support and an attachment element during formation of thecross vehicle beam.

U.S. Pat. No. 5,354,114 discloses an integrated cross car structuralduct cluster. The integrated cross car structural duct cluster of the'114 patent is disclosed as including a steel plate that is attached toa molded plastic body of a thermoplastic or thermoset material.

In accordance with the present invention, there is provided a moldedcross vehicle beam comprising:

(a) a rigid support having a first surface, a second surface and aplurality of perforations having edges;

(b) at least one attachment element having a first surface, a secondsurface and a plurality of perforations having edges, said attachmentelement providing means of attaching said molded cross vehicle beam to aseparate structure; and

(c) a rigid molded member of thermoplastic material, at least a portionof said rigid molded member being in abutting relationship with thefirst surface of said rigid support (a) and the first surface of saidattachment element (b), said rigid molded member having a hollowinterior,

wherein said molded cross vehicle beam is prepared by a processcomprising blow molding a thermoplastic parison precursor of said rigidmolded member (c) onto the first surface of said rigid support (a) andthe first surface of said attachment element (b), a portion of thethermoplastic material of said thermoplastic parison extends through atleast some of said perforations of said rigid support (a) and saidattachment element (b), the edges of said perforations being embedded inthe plastic material extending therethrough, thereby fixedly attachingsaid rigid molded member (c) to said rigid support (a) and saidattachment element (b).

In further accordance with the present invention, there is also provideda method of preparing a molded cross vehicle beam comprising a rigidmolded hollow thermoplastic member fixedly attached to a rigid supportand at least one attachment element, said method comprising:

(I) placing said rigid support and said attachment element in a mold,

said rigid support having a plurality of perforations having edges, afirst surface and a second surface, and

said attachment element having a plurality of perforations having edges,a first surface and a second surface; and

(II) blow molding a thermoplastic parison precursor of said rigid hollowmember against the first surface of said rigid support and the firstsurface of said attachment element;

wherein a portion of the thermoplastic material of said thermoplasticparison extends through at least some of said perforations of said rigidsupport and said attachment element, the edges of said perforationsbeing embedded in the plastic material extending therethrough, therebyattaching fixedly said rigid hollow member to said rigid support and tosaid attachment element.

The features that characterize the present invention are pointed outwith particularity in the claims, which are annexed to and form a partof this disclosure. These and other features of the invention, itsoperating advantages and the specific objects obtained by its use willbe more fully understood from the following detailed description andaccompanying drawings in which preferred embodiments of the inventionare illustrated and described.

Unless otherwise indicated, all numbers or expressions, such as thoseexpressing structural dimensions, quantities of ingredients, etc. usedin the specification and claims are understood as modified in allinstances by the term “about”.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a representative perspective view of a molded cross vehiclebeam according to the present invention, which includes a blow moldedrigid hollow thermoplastic duct 15 that is fixedly attached to a rigidsupport 12 and to attachment elements 81 and 84;

FIG. 2 is a representative perspective view of a portion of the moldedcross vehicle beam of FIG. 1, showing attachment element 84 in furtherdetail;

FIG. 3 is a representation of a section of an attachment means throughline A—A of FIG. 1;

FIG. 4 is a sectional representation of an anchoring extension extendinginto the molded rigid hollow thermoplastic member of a molded crossvehicle beam according to the present invention;

FIG. 5 is a sectional representation of an attachment means similar tothat of FIG. 3;

FIG. 6 is a sectional representation of an attachment means similar tothat of FIG. 3;

FIG. 7 is a sectional representation of an attachment means similar tothat of FIG. 3;

FIG. 8 is a sectional representation of a wrap-around attachment means,in which a portion of rigid hollow member (c) wraps around and embeds atleast a portion of the edges of rigid support (a) therein; and

FIG. 9 is a sectional representation of an embodiment of the presentinvention wherein a portion of attachment element (b) overlaps rigidsupport (a) and at least some of the respective perforations thereof arealigned.

In FIGS. 1 through 9, like reference numerals designate the samecomponents and structural features.

DETAILED DESCRIPTION OF THE INVENTION

Referring now to FIG. 1 of the drawings, there is depicted arepresentative perspective view of a molded composite cross vehicle beam3 according to the present invention. Cross vehicle beam 3 includes aU-shaped rigid support 12 having a plurality of perforations (notshown), a blow molded rigid, continuous and unitary air duct 15 ofthermoplastic material, having a hollow interior 27, and two attachmentelements 81 and 84 each having a plurality of perforations (not shown).Rigid hollow duct 15 is attached to rigid support 12 by means of aplurality of attachment heads 24. Rigid hollow duct 15 is also attachedto attachment elements 81 and 84 by means of a plurality of attachmentheads 93. In addition, rigid hollow duct 15 is attached to rigid support12 and attachment elements 81 and 84 by means of attachment heads 90 (aswill be discussed in further detail herein).

Duct 15 has extensions 18, 21, 30 and 33 which each provide gaseouscommunication with the interior 27 of duct 15. For example, conditionedair (e.g., heated, cooled or dehumidified air) introduced throughextension 21 travels through interior 27 and can exit duct 15 throughextensions 18, 30 and 33. Cross vehicle beam 3 can be used as a crossvehicle beam extending between the door-pillars of a vehicle, such as acar or truck, not shown.

The rigid support (a), e.g., rigid support 12 of cross beam 3, and theattachment element (b), e.g., attachment elements 81 and 84, may eachindependently be fabricated from a material selected from metal,thermoset plastic material, thermoplastic material and combinationsthereof. Metals from which rigid support (a) and attachment element (b)may be fabricated include, but are not limited to, aluminum and steel.In a preferred embodiment of the present invention, rigid support 12 andattachment elements 81 and 84 of cross vehicle beam 3 are eachfabricated from metal, e.g., steel.

As used herein and in the claims the term “thermoset plastic material”means plastic materials having a three dimensional crosslinked networkresulting from the formation of covalent bonds between chemicallyreactive groups, e.g., active hydrogen groups and free isocyanategroups. Thermoset plastic materials from which rigid support (a) andattachment element (b) may each be independently fabricated includethose known to the skilled artisan, e.g., crosslinked polyurethanes,crosslinked polyepoxides and crosslinked polyesters. Of the thermosetplastic materials, crosslinked polyurethanes are preferred. Rigidsupport 12 and attachment elements 81 and 84 may each independently befabricated from crosslinked polyurethanes by the art-recognized processof reaction injection molding. Reaction injection molding typicallyinvolves, as is known to the skilled artisan, injecting separately, andpreferably simultaneously, into a mold: (i) an active hydrogenfunctional component (e.g., a polyol and/or polyamine); and (ii) anisocyanate functional component (e.g., a diisocyanate such as toluenediisocyanate, and/or dimers and trimers of a diisocyanate such astoluene diisocyanate). The filled mold may optionally be heated toensure and/or hasten complete reaction of the injected components. Uponcomplete reaction of the injected components, the mold is opened and themolded article, e.g., rigid support 12, is removed.

As used herein and in the claims, the term “thermoplastic material”means a plastic material that has a softening or melting point, and issubstantially free of a three dimensional crosslinked network resultingfrom the formation of covalent bonds between chemically reactive groups,e.g., active hydrogen groups and free isocyanate groups. Examples ofthermoplastic materials from which rigid support (a), e.g., rigidsupport 12 of cross vehicle beam 3, and attachment element (b), e.g.,attachment elements 81 and 84, may each be independently fabricatedinclude, but are not limited to, thermoplastic polyurethane,thermoplastic polyurea, thermoplastic polyimide, thermoplasticpolyamide, thermoplastic polyamideimide, thermoplastic polyester,thermoplastic polycarbonate, thermoplastic polysulfone, thermoplasticpolyketone, thermoplastic polyethylene, thermoplastic polypropylene,thermoplastic acrylonitrile-butadiene-styrene, thermoplasticpolyvinylchlorine and mixtures or thermoplastic compositions containingone or more thereof. Of the thermoplastic materials from which rigidsupport (a) and attachment element (b) may be fabricated, thermoplasticpolyamides are preferred. Rigid support 12 and attachment elements 81and 84 may each be independently fabricated from thermoplastic materialsby the art-recognized process of injection molding, in which a moltenstream of thermoplastic material, e.g., molten thermoplastic polyamide,is injected into a mold, e.g., an optionally heated mold. Upon coolingthe filled mold, the molded article, e.g., rigid support 12, is removed.A preferred thermoplastic material from which rigid support 12 andattachment elements 81 and 84 may each be fabricated is thermoplasticpolyamide, e.g., DURETHAN thermoplastic polyamide, commerciallyavailable from Bayer Corporation.

The thermoset plastic materials and/or thermoplastic materials fromwhich rigid support (a) and attachment element (b) may each beindependently fabricated, may optionally be reinforced with a materialselected from glass fibers, carbon fibers, boron fibers, metal fibers,polyamide fibers (e.g., KEVLAR polyamide fibers) and mixtures thereof.The reinforcing fibers, and the glass fibers in particular, may havesizings on their surfaces to improve miscibility and/or adhesion to theplastics into which they are incorporated, as is known to the skilledartisan. Glass fibers are a preferred reinforcing material in thepresent invention. If used, the reinforcement material, e.g., glassfibers, is typically present in the thermoset plastic materials and/orthermoplastic materials of rigid support (a) and/or attachment element(b) in a reinforcing amount, e.g., in an amount of from 5 percent byweight to 60 percent by weight, based on the total weight of rigidsupport (a) or attachment element (b).

The thermoplastic material of blow molded rigid hollow member (c), e.g.,duct 15, may be selected independently from those examples recitedpreviously herein with regard to rigid support (a) and attachmentelement (b). In an embodiment of the present invention, thethermoplastic material of blow molded rigid hollow member (c) isselected from at least one of thermoplastic polyolefins (e.g.,thermoplastic polyvinylchloride), thermoplastic polyvinylchlorine,thermoplastic polyurethanes, thermoplastic polyureas, thermoplasticpolyamides, thermoplastic polyesters and thermoplastic polycarbonates.Thermoplastic polyolefins from which the blow molded rigid hollow member(c) may be fabricated include, for example, thermoplastic polyethylene,thermoplastic polypropylene, thermoplastic copolymers of ethylene andpropylene, and thermoplastic polybutylene. In a preferred embodiment ofthe present invention, blow molded rigid hollow member (c) is fabricatedfrom thermoplastic polyamide (e.g., DURETHAN thermoplastic polyamide),commercially available from Bayer Corporation).

The thermoplastic materials from which blow molded rigid hollow member(c) may be fabricated, may optionally be reinforced with a materialselected from glass fibers, carbon fibers, boron fibers, metal fibers,polyamide fibers and mixtures thereof. The reinforcing materials, e.g.,glass fibers, may be treated, e.g., sized, as described previouslyherein with regard to rigid support (a) and attachment element (b). Ifused, the reinforcement material, e.g., glass fibers, is typicallypresent in the thermoplastic materials of blow molded rigid hollowmember (c), e.g., duct 15, in a reinforcing amount, e.g., in an amountof from 5 percent by weight to 60 percent by weight, based on the totalweight of blow molded rigid hollow member (c).

The plastic materials of rigid support (a), attachment element (b) andblow molded rigid hollow member (c) may each independently furthercontain one or more functional additives. Additives that may be presentin the plastic material of the rigid support (a), attachment element (b)and/or the blow molded rigid hollow member (c) of the cross vehicle beaminclude, but are not limited to, antioxidants, colorants, e.g., pigmentsand/or dyes, mold release agents, fillers, e.g., calcium carbonate,ultraviolet light absorbers, fire retardants and mixtures thereof.Additives may be present in the plastic material of the rigid support,attachment element and/or the blow molded rigid hollow member infunctionally sufficient amounts, e.g., in amounts independently from 0.1percent by weight to 10 percent by weight, based on the total weight ofthe plastic material of the rigid support, attachment element or theblow molded rigid hollow member.

As used herein and in the claims, the term “rigid” of rigid support (a),attachment element (b) (when it is rigid) and blow molded rigid hollowmember (c) generally means that the materials from which these elementsare fabricated are self supporting. More specifically, rigid support(a), attachment element (b) (when it is rigid) and blow molded rigidhollow member (c) each typically and independently have a flexuralmodulus of at least 500 MPa, e.g., from 1000 MPa to 15,000 MPa.

Attachment elements 81 and 84 may each independently be rigid orflexible, e.g., fabricated from a elastomeric thermoplastic material.Preferably, attachment elements 81 and 84 are each rigid. In anembodiment of the present invention (not shown), at least one ofattachment elements 81 and 84 is continuous with rigid support 12. Withreference to FIG. 2, a portion 4 of cross vehicle beam 3 of FIG. 1 isshown in greater detail with regard to attachment element 84. Attachmentelement 84 (which is substantially U-shaped) includes a flanged portion96, which includes tabs 99. Each of tabs 99 includes an aperture 102.Flanged portion 96 and tabs 99 are typically designed and shaped suchthat attachment element 84 may be attached to a separate supportstructure, e.g., the door pillar of an automobile (not shown).Attachment element 84 may be fixedly attached to a separate supportstructure, e.g., a door pillar, by means of aligning apertures 102 oftabs 99 with corresponding holes (e.g., threaded holes) in the supportstructure, and then passing fasteners, such as screws or bolts,therethrough, as is known to the skilled artisan. Attachment element 81can be described in a manner similar to that of attachment element 84.

Rigid hollow member (c), e.g., duct 15 of cross vehicle beam 3, isfixedly attached to rigid support (a), e.g., rigid support 12, andattachment element (b), e.g., attachment elements 81 and 84, during theblow molding fabrication of rigid hollow member (c). Rigid support 12and attachment elements 81 and 84, having a plurality of perforations(not shown in FIG. 1), are placed on one side of the blow mold, each oftheir second surfaces facing the interior surface of the mold wall, andeach of their first surfaces facing the open interior of the mold. Arigid thermoplastic feed material, e.g., in the form of pellets, isextruded, typically in an extruder, and the resulting molten extrudateis passed through a die to form a hollow molten tube, which is referredto as a parison. The parison, which is a precursor of duct 15, is drawnthrough or into the open mold into which rigid support 12 and attachmentelements 81 and 84 have been previously placed. The mold is closedaround the parison, pinching off at least one end of the parison.Compressed gas is then fed into the interior of the parison, whichexpands to fill the interior of the closed mold, abutting at least aportion of the first surfaces of rigid support 12 and attachmentelements 81 and 84 therein. A portion of the thermoplastic material ofthe parison extends through at least some of the perforations of support12 and attachment elements 81 and 84 to form attachment heads 24 and 93.In addition, a portion of the thermoplastic material of the parison alsoextends through at least some of the aligned perforations, of theoverlap of attachments elements 81 and 84 with rigid support 12, to formattachment heads 90 (as will be discussed further herein). Whilemaintaining the internal pressure within the parison, the expandedparison is allowed to cool and solidify within the mold. The increasedgaseous pressure within the molded article is released, and the mold isopened, and cross vehicle beam 3 is removed.

A sectional representation through line A—A of an attachment head 24 ofFIG. 1, is depicted as attachment means 5 in FIG. 3. Rigid support 12has a perforation 48 therein. Perforation 48 is defined by deformed edgeportions 36. A portion of the thermoplastic material of duct 15 abutsagainst first surface 42 of support 12, and extends through perforation48 and extends out over a portion of second surface 39 of support 12 toform attachment head 24. The deformed edges 36 of perforation 48 areembedded in the thermoplastic material of duct 15 extendingtherethrough. Attachment head 24 is typically shaped by means ofcorresponding indentations in the interior wall of the mold that arealigned with perforations 48.

In FIG. 3, the hollow interior 27 of duct 15 is in communication withthe hollow interior 45 of attachment head 24. By selecting perforation48 of smaller diameter and/or thermoplastic material of duct 15 ofgreater the thermoplastic material extending through perforation 48 mayfuse together, effectively plugging perforation 48 and forming asubstantially solid attachment head 24 (not shown). Alternatively, thehollow interior 45 of attachment head 24 may not be in communicationwith interior 27 of duct 15, due to plugging (not shown) of perforation48 by the thermoplastic material extending therethrough.

To assist the extension of portions of the parison through theperforations of the rigid support (a), e.g., perforation 48 of rigidsupport 12, and attachment element (b), e.g., attachment elements 81 and84, during the blow molding process, at least one of: (i) increasedgaseous pressure is provided on the interior of the thermoplasticparison; and (ii) reduced gaseous pressure is provided on the secondsurfaces of rigid support (a), for example surface 39 of rigid support12, and attachment element (b), thereby forcing (e.g., drawing and/orpushing) portions of the thermoplastic parison through at least some ofthe perforations. In an embodiment of the present invention, the parisonis extended through the perforations of rigid support (a) and/orattachment element (b) by the concurrent implementation of methods (i)and (ii).

In addition to attachment heads 24, 90 and 93, duct 15 may be furtherfixedly attached to rigid support 12 and attachment elements 81 and 84by attachment means selected independently from fasteners, adhesives andcombinations thereof. Examples of fasteners that may be used in thepresent invention include, but are not limited to, screws, e.g., sheetmetal screws, nuts and bolts, and metal rivets. Adhesives that may beused include those that are known to the skilled artisan, e.g., epoxyresin based adhesives.

As used herein and in the claims, the term “adhesives” refers to: (i)adhesive materials (e.g., epoxy resin based adhesives) that are separatefrom rigid hollow member 15 and each of rigid support 12 and attachmentelements 81 and 84; and (ii) cohesive adhesion between rigid hollowmember 15 and each of the rigid support 12 and attachment elements 81and 84. The materials from which each of rigid support 12, attachmentelements 81 and 84 and duct 15 are fabricated may be selected such thatcohesive adhesion between duct 15 and the other elements results fromtheir mutual abutment. In an embodiment of the present invention, rigidsupport 12 and attachment elements 81 and 84 are each fabricated fromsteel, and each are cohesively adhered to duct 15 which is fabricatedfrom DURETHAN thermoplastic polyamide (commercially available from BayerCorporation.

Additional attachment means in accordance with the present invention aredepicted in FIGS. 4, 5, 6 and 7. Attachment means 7 of FIG. 5 is similarto attachment means 5 of FIG. 3. Attachment head 25 of attachment means5, however, is substantially flush with second surface 39 of support 12.The flush attachment head 25 is formed by means of the interior surfaceof the mold being substantially flush or in abutment with second surface39 of support 12.

Attachment means 8 of FIG. 6 is similar to attachment means 5 of FIG. 3,however perforation 48 is defined by non-deformed edge portions 37.Non-deformed edge portions 37 of perforation 48 are embedded in thethermoplastic material of duct 15 extending there through, which formsattachment head 26. During the blow molding operation attachment head 26is shaped by means of abutment with the interior surface of the mold.

Perforation 48 of attachment means 10 of FIG. 7 is defined by deformededge portions 38, which have a configuration different than that ofdeformed edge portions 36 of FIGS. 3 and 5. Relative to second surface39, the deformed edge portions 36 of FIGS. 3 and 5 tilt in at an angleof less than 90°, while edge portions 38 of FIG. 7 form a substantially90° angle. Deformed edge portions 38 of FIG. 7 are embedded in thethermoplastic material of duct 15 extending there through, which formsattachment head 23. During the blow molding operation attachment head 23is shaped by means of abutment with the interior surface of the mold.

Attachment heads 90 and 93 of attachment elements 81 and 84 may bedescribed in a manner similar to that of attachment heads 24, 25 and 26with reference to FIGS. 3, 5, 6 and 7.

Rigid support (a) and/or attachment element (b) may have extensions,e.g., anchoring extensions, which extend into the thermoplastic materialof rigid thermoplastic hollow member (c). Each extension has walls,e.g., side walls, a hollow interior (e.g., a chamber), and at least oneperforation in its walls. Portions of rigid thermoplastic hollow member(c) extend through the perforations of the anchoring extensions and intothe chamber thereof. In an embodiment of the present invention, all ofthe perforations of the rigid support (a) and attachment element (b) arelocated within the walls of the anchoring extensions, and the rigidthermoplastic hollow member (c) is fixedly attached to rigid support (a)and attachment element (b) by means of the anchoring extensions. Theanchoring extensions may have any desired shape, but are typicallysubstantially cylindrical.

In FIG. 4, a sectional view of an anchoring extension 51 extending intothe thermoplastic material of duct 15 is depicted. Extension 51 haswalls 57 and a perforation 63. Perforation 63 has edges 54 which areembedded in the thermoplastic material of duct 15 which extendstherethrough. The thermoplastic material of duct 15 extending throughperforation 63 forms attachment head 66 within chamber 69 of extension51. Rigid support 12 has a perforation 60 therein which is incommunication with chamber 69 of extension 51. Perforation 60 can beused to form a vacuum within chamber 69, to assist in drawing attachmenthead 66 therein during blow molding operations. To prevent attachmenthead 66 from bursting during the blow molding process, a reversiblyretractable core pin (not shown) may be extended from the interior wallof the mold through perforation 60 into chamber 69 to provide a limitingsurface against which attachment head 66 abuts during its formation, asis known to the skilled artisan. While anchoring extension 51 isdepicted as having only one perforation 63 in FIG. 4, it may have aplurality of perforations through which the thermoplastic material ofduct 15 extends to form additional attachment heads within chamber 69.

An advantage of using anchoring extensions to fixedly attach duct 15 torigid support 12 and/or attachment elements 81 and 84 is the recessionand accompanying protection that is afforded attachment head 66 withinchamber 69. After formation of cross vehicle beam 3, a thermosettingpolymer composition, e.g., a two-pack epoxy or polyurethane composition,may be introduced into chamber 69 by means of perforation 60. Theintroduced thermosetting polymer composition at least partially fillschamber 69 and serves to protect and hold attachment head 66 in place.

Anchoring extension 51 of FIG. 4 may also be used, in addition toattachment elements 81 and 84, to attach the cross vehicle beam assembly3 to a separate structure, e.g., the A-pillars of an automobile (notshown), in an embodiment of the present invention. This can be achieved,for example, by providing threaded portions (not shown) on the edges ofrigid support 12 that define perforation 60, through which a bolt maythen be threaded. Alternatively, a threaded nut (not shown) may beaffixed over perforation 60, e.g., by means of welding, through which abolt may then be partially treaded.

In an embodiment of the present invention, rigid support (a) and/orattachment element (b) have edges which are at least partially embeddedin portions of rigid hollow member (c) that are wrapped there around(wrap-around attachment means). With reference to FIG. 1, portions ofedges 72 and/or 75 of rigid support 12 may be embedded in portions ofthe thermoplastic material of duct 15. A sectional representation of awrap-around attachment means 11 is depicted in FIG. 8. With furtherreference to FIG. 8, edge portion 72 of rigid support 12 has anextension 78 which is embedded in the rigid thermoplastic material ofrigid hollow thermoplastic duct 15. Such wrap-around attachment meansare preferably formed during the blow molding formation of rigid hollowthermoplastic duct 15. Wrap-around attachment means, such as attachmentmeans 11 of FIG. 8, serve to further fixedly attach rigid hollow member(c) to rigid support (a) of the molded article of the present invention.In another embodiment of the present invention (not shown), extension 78of wrap-around attachment means 11 is not present, and edge portion 72is beveled or chamfered (not shown). The beveled edge portion of rigidsupport (a) is at least partially embedded in portions of thethermoplastic material of rigid hollow member (c) that are wrapped therearound.

In an embodiment of the present invention, a portion of attachmentelement (b) overlaps rigid support (a) (e.g., as depicted in FIGS. 1, 2and 9) and/or a portion of rigid support (a) overlaps attachment element(b) (not shown). More particularly: (i) a portion of the first surfaceof attachment element (b) abuts a portion of the second surface of rigidsupport (a); and/or (ii) a portion of the first surface of rigid support(a) abuts a portion of the second surface of attachment element (b). Ineach overlapping embodiment (i) and (ii), at least some of theperforations of attachment element (b) and the perforations of rigidsupport (a) are aligned (the aligned perforations having edges). Aportion of the thermoplastic material of the thermoplastic parisonextends through at least some of the aligned perforations, embedding theedges of the aligned perforations in the plastic material extendingtherethrough. As such, rigid molded member (c) is further fixedlyattached to rigid support (a) and said attachment element (b).

Attachment means 2 of FIG. 9 is formed by an overlap of attachmentelement 84 and rigid support 12, and alignment of their respectiveperforations. See also FIG. 2. More particularly, first surface 105 ofattachment element 84 abuts second surface 39 of rigid support 12. Atleast one perforation of each of attachment element 84 and rigid support12 are aligned and together define aligned perforation 112. Alignedperforation 112 is defined by the overlapping deformed edge portions 118and 36 of attachment element 84 and rigid support 12. A portion of thethermoplastic material of duct 15 abuts against first surface 42 ofsupport 12, and extends through aligned perforation 112 and extends outover a portion of second surface 107 of attachment element 84 to formattachment head 90. The overlapped deformed edges 118 and 36 of alignedperforation 112 are embedded in the thermoplastic material of duct 15extending therethrough. Attachment head 90 is typically shaped by meansof corresponding indentations in the interior wall of the mold that arealigned with perforations 48.

In FIG. 9, the hollow interior 27 of duct 15 is in communication withthe hollow interior 109 of attachment head 90. By selecting alignedperforation 112 of smaller diameter and/or thermoplastic material ofduct 15 of greater thickness, the thermoplastic material extendingthrough aligned perforation 112 may fuse together, effectively pluggingaligned perforation 112 and forming a substantially solid attachmenthead 90 (not shown). Alternatively, the hollow interior 109 ofattachment head 90 may not be in communication with interior 27 of duct15, due to plugging of aligned perforation 112 by the thermoplasticmaterial extending therethrough.

As described previously herein, the extension of a portion of theparison precursor of duct 15 through aligned perforation 112 may beachieved by at least one of: (i) increased gaseous pressure beingprovided on the interior of the thermoplastic parison; and (ii) reducedgaseous pressure being provided on the second surface 107 of attachmentelement 84, thereby forcing (e.g., drawing and/or pushing) portions ofthe thermoplastic parison through at least some of aligned perforations112. In an embodiment of the present invention, the parison is extendedthrough aligned perforations 112 by the concurrent implementation ofmethods (i) and (ii).

The configuration of the overlapping edge portions 118 and 36 of alignedperforation 112 may be deformed, as depicted in FIG. 9. Alternatively,overlapping edge portions 118 and 36 of aligned perforation 112 may haveother configurations, for example selected from those depicted in FIGS.6 and 7.

The cross vehicle beams according to the present invention may be usedin vehicles including, but not limited to: automobiles; trucks; buses;farm equipment; such as combines; and aircraft. In a preferredembodiment of the present invention, the cross vehicle beam is anautomobile cross car beam.

The present invention has been described with reference to specificdetails of particular embodiments thereof. It is not intended that suchdetails be regarded as limitations upon the scope of the inventionexcept insofar as and to the extent that they are included in theaccompanying claims.

What is claimed is:
 1. A molded cross vehicle beam comprising: (a) arigid support having a first surface, a second surface and a pluralityof perforations having edges; (b) at least one attachment element havinga first surface, a second surface and a plurality of perforations havingedges, said attachment element providing means of attaching said moldedcross vehicle beam to a separate structure; and (c) a rigid moldedmember of thermoplastic material, at least a portion of said rigidmolded member being in abutting relationship with the first surface ofsaid rigid support (a) and the first surface of said attachment element(b), said rigid molded member having a hollow interior, wherein saidmolded cross vehicle beam is prepared by a process comprising blowmolding a thermoplastic parison precursor of said rigid molded member(c) onto the first surface of said rigid support (a) and the firstsurface of said attachment element (b), a portion of the thermoplasticmaterial of said thermoplastic parison extends through at least some ofsaid perforations of said rigid support (a) and said attachment element(b), the edges of said perforations being embedded in the plasticmaterial extending therethrough, thereby fixedly attaching said rigidmolded member (c) to said rigid support (a) and said attachment element(b).
 2. The molded cross vehicle beam of claim 1 wherein said rigidsupport (a) and said attachment element (b) are each independentlyfabricated from a material selected from metal, thermoset plasticmaterial, thermoplastic material and combinations thereof.
 3. The moldedcross vehicle beam of claim 2 wherein said rigid support (a) and saidattachment element (b) are each fabricated from metal.
 4. The moldedcross vehicle beam of claim 1 wherein the thermoplastic material of saidrigid molded hollow member (c) is selected from at least one ofthermoplastic polyolefins, thermoplastic polyvinylchlorine,thermoplastic polyurethanes, thermoplastic polyureas, thermoplasticpolyamides, thermoplastic polyesters and thermoplastic polycarbonates.5. The molded cross vehicle beam of claim 1 wherein the thermoplasticmaterial of said rigid molded hollow member (c) is reinforced with amaterial selected from glass fibers, carbon fibers, metal fibers,polyamide fibers and mixtures thereof.
 6. The molded cross vehicle beamof claim 1 wherein said rigid molded hollow member (c) is furtherfixedly attached to at least one of said rigid support (a) and saidattachment element (b) by attachment means selected from fasteners,adhesives and combinations thereof.
 7. The molded cross vehicle beam ofclaim 1 wherein said rigid support (a) and said attachment element (b)have edges, and said rigid molded hollow member (c) is further fixedlyattached to at least one of said rigid support (a) and said attachmentelement (b) by means of at least one of: (i) portions of said rigidmolded hollow member (c) wrapping around and embedding at least aportion of the edges of said rigid support (a); and (ii) portions ofsaid rigid molded hollow member (c) wrapping around and embedding atleast a portion of the edges of said attachment element (b).
 8. Themolded cross vehicle beam of claim 1 wherein said rigid support (a) hasa plurality of anchoring extensions extending into said rigid moldedhollow member (c), each of said anchoring extensions having walls, aninterior chamber and at least one wall perforation in said walls, eachwall perforation having edges, a portion of said rigid molded hollowmember (c) extends through at least some of said wall perforations intosaid chamber, the edges of said wall perforations being embedded in theplastic material extending therethrough, thereby fixedly attaching saidrigid molded hollow member (c) to said rigid support (a).
 9. The moldedcross vehicle beam of claim 1 wherein said attachment element (b) has aplurality of anchoring extensions extending into said rigid moldedhollow member (c), each of said anchoring extensions having walls, aninterior chamber and at least one wall perforation in said walls, eachwall perforation having edges, a portion of said rigid molded hollowmember (c) extends through at least some of said wall perforations intosaid chamber, the edges of said wall perforations being embedded in theplastic material extending therethrough, thereby fixedly attaching saidrigid molded hollow member (c) to said attachment element (b).
 10. Themolded cross vehicle beam of claim 1 wherein said rigid molded hollowmember (c) is a continuous unitary molded hollow member.
 11. The moldedcross vehicle beam of claim 1 wherein said molded cross vehicle beam isan automotive molded cross vehicle beam.
 12. The molded cross vehiclebeam of claim 10 wherein said rigid molded hollow member (c) is an airduct.
 13. The molded cross vehicle beam of claim 1 wherein at least someof said perforations of said rigid support (a) have deformed edgeportions, and said deformed edge portions are embedded in the plasticmaterial extending therethrough.
 14. The molded cross vehicle beam ofclaim 1 wherein at least some of said perforations of said attachmentelement (b) have deformed edge portions, and said deformed edge portionsare embedded in the plastic material extending therethrough.
 15. Themolded cross vehicle beam of claim 1 wherein during the blow moldingstep, at least one of: (i) increased gaseous pressure is provided on theinterior of said thermoplastic parison; and (ii) reduced gaseouspressure is provided on the second surface of at least one of said rigidsupport (a) and said attachment element (b), thereby forcing portions ofsaid thermoplastic parison through at least some of said perforations ofsaid rigid support and said attachment element.
 16. The molded crossvehicle beam of claim 1 wherein said attachment element (b) is a rigidattachment element.
 17. The molded cross vehicle beam of claim 16wherein said rigid attachment element (b) is continuous with said rigidsupport (a).
 18. The molded cross vehicle beam of claim 1 wherein atleast one of: (i) a portion of the first surface of said attachmentelement (b) abuts a portion of the second surface of said rigid support(a); and (ii) a portion of the first surface of rigid support (a) abutsa portion of the second surface of said attachment element (b), witheach of (i) and (ii) at least some of the perforations of saidattachment element (b) and the perforations of said rigid support (a)are aligned, the aligned perforations having edges, a portion of thethermoplastic material of said thermoplastic parison extends through atleast some of the aligned perforations, the edges of the alignedperforations being embedded in the plastic material extendingtherethrough, thereby further fixedly attaching said rigid molded member(c) to said rigid support (a) and said attachment element (b).